Independent Verification for a Safe and Controlled Plant Start-Up
At Lion Safety Consulting, we conduct Pre-Startup Safety Reviews (PSSR) to ensure that your facility is fully prepared for safe start-up. PSSR is a structured, practical assessment that verifies whether design, documentation, technical safeguards, operating procedures, and organizational arrangements are ready before introducing energy, utilities, or hazardous substances into the plant. As the final critical step before commissioning, PSSR helps identify gaps that could lead to incidents, equipment damage, delays, or increased operational risk.
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Clients Across World
From Hazard Identification to Quantified Risk
Quantitative Risk Evaluation for Critical Safety Decisions.
Independent PSSR before plant start-up. We verify technical, procedural, and organizational readiness, identify critical gaps, and support a safe, controlled commissioning process.The client receives an independent and practical assessment of start-up readiness together with a clear list of actions to be closed before start-up or immediately afterwards, in line with the agreed risk priority.
Our Approach to PSSR:
Independent Review
We facilitate the PSSR process independently and objectively, ensuring unbiased assessment of the plant’s readiness for start-up.
Documentation Check
We verify that all design documentation, process safety requirements, and follow-up actions from HAZOP, LOPA, and SIL analyses are complete and accurate.
Operational Readiness Assessment
We evaluate the status of procedures, emergency protocols, and start-up processes to confirm they are fully prepared for safe commissioning.
Field Verification
Our experts conduct site visits and workshops to inspect equipment, verify safeguards, and validate readiness in practice.
Findings & Prioritization
We provide a structured findings register, classify actions by priority, assign responsibilities, and set target closure dates to ensure timely risk mitigation.
What exactly is PSSR and why do you need it?
PSSR is a structured and practical review of a facility’s readiness for safe start-up. The purpose of this service is to confirm that the design, documentation, technical safeguards, operating procedures and organisational arrangements are sufficiently prepared before introducing energy, utilities or hazardous substances into the plant.
In practice, PSSR is the final critical verification step before start-up. It helps identify gaps that could otherwise lead to process incidents, equipment damage, commissioning delays or an uncontrolled increase in operational risk.
Our PSSR approach is based on independent and objective facilitation of the review process. We assess the plant’s level of readiness against design documentation, process safety requirements, HAZOP / LOPA / SIL follow-up actions, operational preparedness and the status of open actions. The review concludes with a clearly structured findings register, priority classification and support in assigning owners and target closure dates.
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Clients Across World
PSM Implementation
Building and implementing a Process Safety Management system
Effective process safety is not built on individual studies alone, such as HAZOP or LOPA. It requires a consistent management system that connects design, operations, maintenance, team competence, management of change and risk control throughout the full lifecycle of the facility. This is the purpose of Process Safety Management.
We support clients in building and implementing practical PSM systems tailored to the actual risk profile of the plant, project phase, and organisational and regulatory expectations. Our approach is focused not on producing static documentation, but on implementing solutions that work in day-to-day operations.
The service may cover a full PSM implementation from the ground up, as well as gap assessments, improvement of existing practices and development of selected PSM elements. We work with both greenfield projects, where the system must be built before start-up, and existing facilities seeking to improve process safety maturity.
Depending on client needs, we support implementation of elements such as:
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Safety Policy & Governance
We help define your process safety policy, management structure, and governance model, ensuring clear accountability and effective oversight across all organizational levels.
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Roles, Responsibilities & Competence
Establishing clear roles, responsibilities, and a training framework to ensure staff have the knowledge and skills required to manage process safety effectively.
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Process Knowledge & Documentation
Management of technical documentation, process safety information, and control of operational records to maintain up-to-date and accessible data for safe operations.
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Hazard & Risk Analysis Management
Integration and follow-up of HAZID, HAZOP, LOPA, SIL, and related action items, ensuring hazards are identified, analyzed, and mitigated systematically.
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Procedures & Operational Readiness
Development and control of operating, start-up, emergency, and shutdown procedures, along with PSSR and start-up readiness checks to confirm safe operations.
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Management of Change & Continuous Improvement
Implementing process-safety-driven Management of Change (MoC) and monitoring key indicators, incidents, and improvement actions to continuously enhance safety performance.
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Safety Metrics & Performance Monitoring
Establishing measurement systems to track process safety performance, ensuring risks are controlled and progress is visible.
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Training & Competence Development
Tailored training programs to develop personnel competence in managing hazards and safety-critical functions.
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Documentation & Compliance Control
Ensuring all PSM-related documentation meets regulatory requirements and internal standards, supporting audits and inspections.
Clear, Compliant, and Long-Term Safety Management
Our objective is to build a system that is clear, auditable and sustainable for the organisation in the long term. Such a system supports compliance, improves risk control and strengthens protection of people, the environment and operational continuity.
Typical engagement models:
• Gap assessment of the existing framework,
• PSM implementation roadmap for a new project,
• Development of procedures and internal standards,
• Workshops on roles and responsibilities,
• Implementation support for EPCM, owner and operations teams,
• Start-up readiness preparation and support for ongoing operations.
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Clients Across World
Our latest realisations
From PSSR & PSM services:
Warehouse Safety Optimization for NovaLogistics Group
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"Your safety is our duty"
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